Strut system

ABSTRACT

A device for providing structural support comprising a longitudinal slot formed with inwardly projecting longitudinal flanges, and a support member extending outwardly opposite the longitudinal slot. Some embodiments may include a support member having a stop formed longitudinally along the edge of the support member. Other embodiments may include a plurality of longitudinal protuberances and/or detents. In addition, holes may be disposed in the support member and the support member may be formed with decorative elements to effectuate a particular design.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. Provisional Patent Application No. 61/229,463, entitled “Luminaire System and Method” filed Jul. 29, 2009 by the inventors George Mieling, Thomas Warton and Scott S. Yu, which is incorporated herein by reference.

BACKGROUND

The present invention relates generally to mechanical systems, and more particularly to an improved strut design for supporting a structure such as lighting systems and the like.

Related art describes a wide variety of luminaires. Some of these relate to luminaire assemblies (U.S. Pat. No. 7,686,483), others relate to particular types of mounts (U.S. Pat. No. 7,686,470). The luminaire described by Bishop (U.S. Pat. No. 5,526,244) provides for a strut, but this strut does not provide for the modularity and ease of assembly of the present invention. A strut is described by Orlov (U.S. Pat. No. 6,517,222) provides support for a luminaire, but, again, does not provide for modularity and ease of assembly.

What is needed is an improved strut that allows for modularity and ease of assembly, while providing additional strength and rigidity to the strut and any supported structure.

SUMMARY

Disclosed herein is a device for providing structural support comprising a longitudinal slot formed with inwardly projecting longitudinal flanges, and a support member extending outwardly opposite the longitudinal slot. Some embodiments may include a support member having a stop or detent formed longitudinally along the edge of the support member. Other embodiments may include a plurality of longitudinal protuberances and/or detents. In addition, holes may be disposed in the support member and the support member may be formed with decorative elements to effectuate a particular design.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an assembled luminaire system.

FIG. 2 illustrates a coupling device for use in a luminaire system

FIG. 3 illustrates a disassembled luminaire system.

FIG. 4 shows different light rails that may be used with a luminaire system

FIG. 5 illustrates an end view of certain embodiments of a strut.

FIG. 6 illustrates embodiments of a strut.

FIG. 7 illustrates differing views of certain embodiments.

DESCRIPTION

Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

FIG. 1 illustrates fixture support system. In FIG. 1, a luminaire assembly 100 is depicted suspending from an overhead. The suspension assembly 110 includes both a structural cable, together with an electrical power cable 120. It is connected to a chassis 114 which may provide an enclosure for an electrical ballast (not shown). One end of the chassis 114 is attached to a support arm 116, and the chassis 114 may have an additional support arm 126. The support arm 116 is slidably coupled to the chassis 114 such that the support arm 116 can be adjusted in relationship to the chassis 114. Likewise a support arm 126 is slidably coupled to the chassis to allow it to move for better positioning. Depending on the length of the chassis 114 many other support arms can be added in series. The support arms are cross members in relation to the chassis 114. Slidable coupling may be effectuated using set screws or other mechanisms to allow for sliding of the arms and then locking them in place once set.

The chassis 114, the support arm 116 and other parts of the fixture support system described below may be formed by available processes, including, but not limited to: extrusion, molding or machining. The material may be any suitable material providing sufficient strength and other properties, including but not limited to: aluminum, steel, ceramics or plastics.

The support arms 116, 126, (and others) are designed to hold in place light rails 118. The light rails as shown in the FIG. 1 include a reflector formed to direct light towards a particular direction and connectors such as sockets and plugs for connecting to a light source. The light source may be electrically coupled to a power source through the power cable 120. The light rails 118 are connected to the support arms by hub assemblies 124. The light rails 118 are designed to protect a lighting device and may include clear shields, baffles and other structures effectuating a similar result. The hub assembly 124 allows for rotation of the light rails 118, thus allowing users to configure the direction of the light from the light rails 118. The hub assemblies 124 also provide for coupling electrical power from the support arms to the light rail and its associated lighting device.

The suspension assembly 110 is coupled to two suspension wires 112 which may be formed from a single wire, joined to the suspension assembly 110 thus having two separate tensions. A coupling device 122 provides for coupling the suspension wires 112 to the suspension assembly 110 and for the adjustment of the suspension wires 112. The coupling device 122 secures suspension wires 112 to the suspension assembly 110 using a fastener such as a set screw (not shown). The coupling device 122 allows for height adjustment on the suspension assembly 110, and a lateral adjustment on the suspension wires 112.

In the FIG. 1 power to the luminaire is supplied along the suspension assembly 110 and to the power wire 120 into the chassis 114. From the chassis 114 power can be applied to the light rails 118 in several different ways. Power can be routed through the arms 116 and 126 and associated hubs to reach each end of the light rail 118. Or power could be routed through one of the arms 116 or 126 to reach a single end of the light rail 118, having an additional power line run through the light rail to reach the other end of a lighting device located inside the light rail 118. The lighting device may be either incandescent, fluorescent or LED Assembly and the like.

In operation an assembler would suspend the fixture using the suspension assembly 110. After the fixture is suspended, adjusting the coupling device 122 and the support arms 116 and 126, to true the entire fixture. This allows for easy installation because variations in the installation can be easily rectified simply by adjusting the support arms 116 and 126 and the coupling device 122. In addition, multiple fixtures such as the one shown in the FIG. 1 may be suspended side-by-side. By adjusting the coupling device 122 and the support arms 116 and 126, the fixtures can be trued to each other.

Coupling Device

FIG. 2 shows a coupling device 200 for use in a luminaire system. The coupler 214 may be manufactured from any solid material capable of handling the stress depending on the application, preferably a metal such as steel or aluminum. The coupler 214 has a bore through one axis were a cable 210 is passed through the coupling device 200. A set screw 218 (or similar fastener) is disposed through the coupler 214 to exert pressure on the cable 210 to lock the coupler 214 in place on the cable 210. The coupler 214 must be capable of withstanding threading to allow the set screw 218 to function properly and secure the cable 210.

The coupler 214 has a second bore offset from the first bore for accommodating a cable 212. The second cable is secured byte set screw 216. In operation, the coupler 214 allows for relative positioning of two cables in close proximity and for easy adjustment and alignment of the two cables 210 and 212 in relation to each other.

References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure or characteristic, but every embodiment may not necessarily include the particular feature, structure or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one of ordinary skill in the art to affect such feature, structure or characteristic in connection with other embodiments whether or not explicitly described. Parts of the description are presented using terminology commonly employed by those of ordinary skill in the art to convey the substance of their work to others of ordinary skill in the art.

FIG. 3A illustrates a partially disassembled luminaire system. In the FIG. 3A a luminaire assembly 300 is depicted suspended from an overhead mount. The suspension assembly 310 may include both a structural cable and electrical power cable 320. The suspension assembly 310 may also be formed from a solid material such as metal or plastic rod. The suspension assembly 310 is connected to a strut 324 which acts as a chassis for connecting to a ballast housing 314. The ballast housing 314 need not contain a ballast. One end of the ballast housing is attached to a support arm 316, and the ballast housing 314 may be connected to an additional support arm 326. The support arm 316 is slidably coupled to the ballast housing 314 through the use a groove positioned on an end of the ballast housing 314 such that the support arm 316 is placed in the groove and can slide to different positions in the groove. The support arm 316 can be adjusted in relationship to the ballast housing 314. Likewise a support arm 326 is slidably coupled to the ballast housing to allow it to move for better positioning. Depending on the length of the ballast housing 314 many other support arms can be added in series. Slidable coupling may be effectuated using set screws or other mechanisms to allow for sliding of the arms and then locking them in place once set in position.

Ballast In Arm

One having skill in the art will appreciate that the ballast housing 314 may be alternatively designed to allow for more structural support. By locating a ballast into the support arm 316 or 326, the ballast housing may need to be manufactured from material having different strength characteristics or shaped differently from that show in the FIG. 3A. Relatively small ballasts are commercially available (B & L Model NU6-1128-MSN/D for example) and support arms may be manufactured to completely house the ballast. A modified strut may be added to the ballast housing 314, or if the ballast is located in a support arm or if a ballast is not needed, a modified strut may replace the ballast housing 314.

Enhanced Strut

FIG. 3B shows a strut 324 that may be used to support ballast. This strut is held by the suspension assembly. The channel support 350 may be formed from conventionally available “strut channel” often used in construction. Added to the channel support 350 is a support member 352 extending along the length of the channel support 350. The support member 352, by increasing the moment of inertia, has the affect of strengthening the channel support 350 and reducing the deflection due to bending, torsional or twisting forces on the channel support 350. This support member may be made of any solid material. In some embodiments the strut 324 is formed by extruding aluminum through a form. In addition, the strut 324 may be formed by bending sheet metal or through machining. The strut 324 may also be formed from non-metallic components such as plastics. For example, the strut 324 may be form by injection molding of plastics.

Channel support 350 may be formed to any desired length, and the support member 352 may be welded on or otherwise affixed, or optionally extruded when formed. Also, the support member need not be continuous, but may be formed from several pieces positioned about the channel support 350 to achieve the desired result. Strut 324 is affixed to the ballast housing 314 or a ballast by an affixing means such as slide-on connectors, spring-loaded clamps, screws, clamps and any other affixing means that can provide a strong enough connection between the two to provide adequate physical support. The suspension assembly(s) are affixed to the strut via attachment points to the support member. In an alternative embodiment, the strut is attached directly to a surface such as a wall, ceiling or piece of furniture via attachment points to the support member.

Referring to FIG. 5A, the strut 324 is generally a U-shaped channel 350 having a support member 352 extending vertically from the top. A perspective view of this embodiment it shown in FIG. 5B. The longitudinal sides 510 are turned inward forming a bottom side 520. The opening between these upturned sides form a longitudinal slot. The edges of the bottom sides may be turned inward again so as to produce an inturned longitudinal flange 530. The top portion of the support member 352 may be expanded to form a stop (FIG. 6) that runs longitudinally along the length of the support member. This stop may have a rectilinear 610 or curvilinear 620 cross-section. One or more protuberances 630 or detents 640 may be located along the sides of support member 352 and run longitudinally along the length of the support member. The stops, protuberances and detents can be engaged by clamps or other elements and can be engaged by the suspension assembly. Holes 710 may be incorporated in the support member (FIG. 7). These holes 710 can be engaged by clamps or other elements and can be engaged by the suspension assembly. These holes may be of a rectilinear or curvilinear cross-section.

In addition the structural member 352 may be formed with decorative elements or the protuberances and detents may be formed to effectuate a decorative design. In a luminaire system, the shape of the structural member 352 may be effectuated in various ways to conform to the luminaire system.

The support arms 316, 326, (and others, not shown) are designed to hold in place light rails. The suspension assembly 310 is coupled to two smaller suspension wires 312 which may be a single wire. The wires 312 are fastened to the support arm 316, but alternatively, the ends of the wires may be formed as a catch, with the affect of allowing the ends of the wires 312 to be disposed into a “key hole.” The key hole formed with a larger portion for accepting the catch and a smaller portion for holding the catch in place. A coupler 322 provides for the adjustment of the suspension wires 312 and secures them in place with a set screw (not shown). The coupler 322 allows for height adjustment on the suspension assembly 310, and a lateral adjustment on the suspension wires 312.

Power to the luminaire is supplied along the suspension assembly 310 and to the power wire 320 then into the ballast housing 314. From the ballast housing 314 power can be applied to the light rails in several different ways. Power can be routed through the arms 316 and 326 to reach each hub 124 which is at the end of the light rail 118. Or power could be routed through one of the arms 316 or 326 to reach a single end of a light rail having an additional power line run through the light rail to reach the other end of a lighting device located inside the light rail if necessary.

In operation, an assembler would suspend the luminaire using the suspension assembly 310. After the luminaire is suspended, adjusting the coupler 322 and the support arm swing 316 and 326, to true the entire assembly. This allows for easy installation because minor variations in the installation can be easily rectified simply by adjusting the support arms 316 and 326 and the coupler 312.

FIG. 4 shows an assortment of light rails 400 that may be used with a luminaire system. In the FIG. 4 a baffle 410 provides for a covering over a light source that has the effect of allowing light out of the rail, but reducing glare when viewed from a side angle. The baffle 410 may be manufactured from semi-rigid material such that the baffle 410 snaps into the light rail and is thus held securely by compression. Alternatively, a baffle may be fastened in place by coupling it to the light rail using conventional fasteners such as screws and bolts. The baffle 410 as shown includes structure 414 to secure the baffle to an elongated lamp thus allowing the baffle 410 to hang suspended from the lamp.

In a luminaire system different light rails may be employed by coupling them to a hub 412, such that the hub provides mechanical support, pivotability and a means to provide the light source with electrical power.

The above illustration provides many different embodiments or embodiments for implementing different features of the invention. Specific embodiments of components and processes are described to help clarify the invention. These are, of course, merely embodiments and are not intended to limit the invention from that described in the claims.

Although the invention is illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims. 

We claim:
 1. A device comprising: a longitudinal slot; inwardly projecting longitudinal flanges, and a support member extending outwardly opposite the longitudinal slot.
 2. The strut of claim 1 wherein the support member further includes a stop, said stop formed longitudinally along the edge of the support member.
 3. The strut of claim 1 wherein the support member further includes a plurality of longitudinal protuberances and/or detents.
 4. The strut of claim 2 wherein the support member has a plurality of said longitudinal protuberances and/or detents.
 5. The strut of claim 1 wherein the support member has a plurality of holes passing through the support member
 6. A device comprising: an elongated member having a first surface, a first and a second side, said first and second side having an inward turn to created a slot opposite the first surface, and a support member disposed orthogonally to the first surface projecting substantially perpendicular to the plane of the flange and substantially perpendicular to the plane of the longitudinal axis, said support member substantially the length of the elongated member.
 7. The device of claim 6 wherein the support member has a through hole.
 8. The device of claim 6 wherein the support member has a detent or a protuberance.
 9. A method comprising: suspending a cable; attaching a fastener to a first end of a cable; coupling the fastener to a strut, said strut having a channel and a support member.
 10. The method of claim 9 further including: connecting a housing to the strut.
 11. The method of claim 9 further including: connecting a support arm to the strut. 